ROOF STRUCTURE

Abstract: The invention is concerned with an improved method of roofing and a roof structure provided by said method. The improved method of roofing comprises the steps of: a) providing a roof structure including spaced rafters (2); b) locating panels (4) between associated pairs of said rafters to form a closed roof structure; c) procuring a plurality of carrier frames (6) for roofing tiles (8); d) mounting at least one tile (8) on each carrier frame (6); and e) fixing said frames (6) to said panels (4); wherein said panels (4) each comprise recesses (24) adapted to receive, in use, associated protuberances (42) of the carrier frames (6) whereby said frames (6) and the tiles (8) mounted thereon are fixed to the roof structures as aforesaid. An advantage of the present invention is that it provides a quick and easy method of constructing a roof structure which avoids the use of nails, clips and pegs and other such fixing arrangements.

Description: ROOF STRUCTURE This invention is concerned with improvements in or relating to a method of roofing and a roof structure provided by said method. Conventional roof structures for dwellings usually comprise spaced rafters to which are secured an impervious membrane, e.g. a felt underlay, and spaced roofing battens. Roof tiles are located by hanging nibs on the battens the tiles being secured thereto by a variety of fasteners, e.g. nails, clips and pegs or a combination of such devices. Recognising the high cost and labour intensive nature of present roof structures, one recent patent applicant, in EP 0515012A, discloses and describes a roof insulation board adapted for anchoring roof tiles. However, the tiles merely lie on the insulation board of the alleged invention with hanging nibs thereof being received in oversize channels of the board and such tiles would be readily removed from the roof in inclement weather conditions. In Europe, the USA and Japan, it is also well known to make a panelled roof wherein panels of wood or an insulation material are secured between or on spaced rafters. In a further system, sheathed rafter panels may be used. Irrespective of which variant of roof structure is utilised, roof tiles located thereon are also secured by a variety of fasteners as herein¬ before defined. Thus, the roof tiles of EP 0516012A, in order to provide a secure roof structure, would need to be secured by appropriate fasteners adding to the labour content while increasing the overall cost of such a roof. The present invention seeks to overcome or at least mitigate the disadvantages of known roof structures; thus, the present invention provides a method of roofing comprising the steps of: a) providing a roof structure including spaced rafters; b) locating panels between associated pairs of said rafters to form a closed roof structure; c) procuring a plurality of carrier frames for roofing tiles; d) mounting at least one tile on each carrier frame; and, e) fixing said frames to said panels; wherein said panels each comprise recesses adapted to receive, in use, associated protuberances of the carrier frames whereby said frames and the tiles mounted thereon are fixed to the roof structures as aforesaid. Conveniently said protuberances extend downwardly and forwardly of a roof in use to be received in said recesses which extend upwardly and rearwardly of a roof in use, said protuberances preferably being provided towards or at a lower end portion of said carrier frames. In a method of roofing according to the present invention a first horizontal row of tiles is laid on the roof by locating said protuberances of successive carrier frames in the recesses by successively canting upper end portions of each frame away from the roof structure and introducing the protuberances thereof into the recesses of the panels associated therewith, the successive carrier frames thereafter being turned about their lower end portion towards the roof structure to cause their respective protuberances to be received in captive engagement in said recesses. Conveniently successive horizontal rows of tiles are laid on the roof with tail end portions of the tiles in each successive horizontal row being arranged in overlapping relationship with associated headlap portions of the tiles in a row of such tiles located therebelow and an uppermost horizontal row of tiles on a roof is secured at their headlap portions adjacent a ridge of the roof whereby all of the tiles on a roof of such tiles are mutually interlocked one with another without the use of conventional fasteners as hereinbefore defined. The present invention also provides a roof structure comprising: a) spaced rafters of conventional design; b) panels extending between associated pairs of said rafters to form a closed roof structure; c) a plurality of carrier frames for roofing tiles; d) a plurality of roofing tiles secured at least one each to said carrier frames; and, e) means for securing said carrier frames and thus said roofing tiles to said panels, said means comprising associated protuberances and recesses provided on said carrier frames and in said panels respectively, wherein, in use, said recesses are adapted to receive associated protuberances of the carrier frames whereby said frames and the tiles mounted thereon are fixed to the roof structure. Preferably the panels each comprise ridges extending laterally of the panels in use, said ridges being parallel or substan¬ tially so one with another and being provided with said recesses for receiving the protuberances of associated carrier frames. Preferably the panels are generally rectangular in plan and each comprises interlocking sidelock portions and overlapping head and tail portions, such panels being of a lightweight insulation material. Conveniently the carrier frames are generally rectangular in plan and each comprises headlap and sidelock engaging clip portions arranged to be a snap-fit, in use, over associated headlaps and sidelocks of tiles carried thereby which carrier frame is provided by a plastics moulding and the protuberances thereof are provided by downwardly extending and forwardly facing hook portions adapted to be received in use in said recesses. The tiles used herein may be conventional interlocking tiles which are generally rectangular in plan each tile comprising conventional headlap and sidelock portions for interengagement with adjacent tiles on a roof and the panels may conveniently be of moulded material, e.g. plastics which panels are fastened to associated pairs of rafters of said structure. There now follows, by way of example of the invention in its method and roof structure aspects, a detailed description which is to be read with reference to the accompanying drawings in which: Figure 1 is an upper left hand perspective view of a carrier frame with one roof tile located thereon; Figure 2 is a view corresponding to Figure 1 but with two interlocking tiles located thereon; Figure 3 is an upper left hand perspective view of a panel provided by the present invention; Figure 4 is a section view taken on the line IV-IV of Figure 8; Figure 5 is a side elevation of two panels illustrating an interlocking feature thereof; Figures 6 and 7 are part side elevations illustrating the interengagement between the carrier frames and the panels of the present invention; and, Figure 8 is a side sectional view of the novel roof structure provided by the present invention. Hitherto conventional roof structures have been at a disad¬ vantage because, in order to secure roof tiles thereon against inclement weather conditions, it has been the practice to utilise a variety of fasteners, e.g. nails, clips and pegs or a combination of such devices. Such practices have added to the labour content in constructing a roof and as a consequence roofing costs are understandably high. In overcoming the disadvantages of prior practices and provid¬ ing an easily assembled roof structure at acceptable cost, the present invention provides a roof structure which generally comprises conventional equi-spaced rafters 2, panels 4 located along and up the roof between associated pairs of said spaced rafters 2 to form a closed roof structure as shown in side elevation in Figure 8, carrier frames 6 each supporting two tiles 8 as shown in Figure 2, which carrier frames 6 are secured to the panels 4 as described hereinafter to complete the roof structure. The panels 4 are generally rectangular in plan each panel comprising left and right hand interlocking edge portions 10 and 12 with the portion 10 facing upwardly and the portion 12 facing downwardly as shown in Figures 3 and 4. The panels also each comprise an upwardly facing stepped headlap portion 14 and a complementary downwardly facing stepped tail end portion 16, see Figures 5 and 8. Each panel 4 comprises upper and lower spaced lateral ridges 18 and 20 on an upper surface 22 thereof. The ridges 18 and 20 are each recessed at 24 which recesses 24 are arcuate in cross-section and extend upwardly and rearwardly in use, i.e. when the panels 4 are assembled on a roof as described hereinafter. The ridges 18 and 20 also each comprise a series of recesses 26 along the lengths thereof, see Figure 3, the purpose of which is to facilitate the escape of any moisture from the underside of the tiles laid on a roof as described hereinafter. The panels 4 are moulded from reinforced polystyrene although any suitable insulation material of sufficient strength or one which is suitably reinforced may be utilised. The carrier frames 6 are generally rectangular in plan and are each provided by a plastics moulding comprising integral head¬ lap engaging clips 34 arranged in two associated pairs at upper end portions 36 of each frame 6. Each carrier frame 6 also comprises two integral sidelock engaging clips 38 at a lower end portion 40 thereof, see Figure 1. For effecting interengagement, as hereinafter described, with the panels 4, each carrier frame 6 comprises an integrally formed protuberance provided by a series of hook portions 42, see Figure 1, which hook portions 42, in use, extend downwardly and forwardly of the frame 6 and the roof structure as herein¬ after described. Each carrier frame 6 also comprises tile retaining means 44 provided by triangular bosses 46 only one of which is shown in Figure 1, the function of which will be described hereinafter. For ease of carrying, each frame 6 is provided with an integrally moulded handle 48 extending from its upper end portion 36 thereof. In assembling the novel roof structure by the method of roofing provided by this invention a roofer: a) constructs a roof including equi-spaced rafters 2 of conventional design; b) locates panels 4 along and up the roof between associated pairs of said equi-spaced rafters 2, the arrangement being such that underside rebated portions 50 and 52 of the panels 4 are located on said rafters as shown in Figure 4 with the sidelock portions 10 and 12 thereof in interengagement also as shown in Figure 4 and with the headlap and tail end portions 14 and 16 thereof respec¬ tively in interengagement as shown in Figure 5; c) procures a supply of carrier frames 6 to each of which he attaches two interlocking planar tiles 8 as shown in Figures 1 and 2 with nib portions of each tile locating behind associated bosses 46 of the tile retaining means 44 and with the respective sidelock portions of the two tiles in mutual engagement as shown in Figure 3; d) carries the frames 6 with the tiles thereon to the roof using the handles 48; e) positions a first row of frames 6 and tiles 8a at the eave of the roof by canting upper end portions of each frame 6 away from the roof structure, as shown in Figure 6, and introducing the hooks 42 thereof into the recesses 24 associated therewith, the frames 6 and the tiles 8a carried thereby are thereafter turned about their lower end portions towards the roof structure to cause respec¬ tive hooks 42 to be fully received in captive engagement in said associated recesses 24 as shown in Figures 7 and 8 and with the sidelock portions 10 and 12 of the frames 6 being arranged in mutual interengagement along the said first row of frames 6 as shown in Figure 4; f) repeats the procedure of step e) above in respect of successive rows of frames 6 and tiles 8b to 8f as shown in Figures 7 and 8 with tail end portions of the tiles 8a to 8f in each successive horizontal row arranged in over¬ lapping relationship with associated headlap portions of the tiles 8 in a row of such tiles located immediately therebelow: and, g) secures an uppermost horizontal row of frames 6 and tiles 8 adjacent a ridge of the roof structure whereby all of the frames 6 and tiles 8 are mutually interlocked one with another without the use of conventional fasteners as hereinbefore defined. Although not mentioned herein, if required, the panels 4 may be secured to the rafters 2 by any suitable means. Modifications and refinements may be made to the novel roof structure within the scope of the invention.

Claims: CLAIMS 1. A method of roofing comprising the steps of: a) providing a roof structure including spaced rafters; b) locating panels between associated pairs of said rafters to form a closed roof structure; c) procuring a plurality of carrier frames for roofing tiles; d) mounting at least one tile on each carrier frame; and, e) fixing said frames to said panels; wherein said panels each comprise recesses adapted to receive, in use, associated protuberances of the carrier frames whereby said frames and the tiles mounted thereon are fixed to the roof structures as aforesaid. 2. A method of roofing according to Claim 1 wherein said protuberances extend downwardly and forwardly of a roof in use to be received in said recesses which extend upwardly and rearwardly of a roof in use. 3. A method of roofing according to either one of Claims 1 and 2 wherein the protuberances are provided towards or at a lower end portion of said carrier frames. 4. A method of roofing according to Claim 3 wherein a first horizontal row of tiles is laid on the roof by locating said protuberances of successive carrier frames in the recesses by successively canting upper end portions of each frame away from the roof structure and introducing the protuberances thereof into the recesses of the insulation boards associated therewith, the successive carrier frames thereafter being turned about their lower end portion towards the roof structure to cause their respective protuberances to be received in captive engagement in said recesses. 5. A method of roofing according to Claim 4 wherein succes¬ sive horizontal rows of tiles are laid on the roof with tail end portions of the tiles in each successive hori¬ zontal row being arranged in overlapping relationship with associated headlap portions of the tiles in a row of such tiles located therebelow. 6. A method according to Claim 5 wherein an uppermost hori¬ zontal row of tiles on a roof is secured at their headlap portions adjacent a ridge of the roof whereby all of the tiles on a roof of such tiles are mutually interlocked one with another without the use of conventional fasteners as hereinbefore defined. 7. A roof structure comprising: a) spaced rafters of conventional design; b) panels extending between associated pairs of said rafters to form a closed roof structure; c) a plurality of carrier frames for roofing tiles; d) a plurality of roofing tiles secured at least one each to said carrier frames; and, e) means for securing said carrier frames and thus said roofing tiles to said panels, said means comprising associated protuberances and recesses provided on said carrier frames and in said panels respectively, wherein, in use, said recesses are adapted to receive associated protuberances of the carrier frames whereby said frames and the tiles mounted thereon are fixed to the roof structure. 8. A roof structure according to Claim 7 wherein said protu¬ berances extend downwardly and forwardly of a roof in use to be received in said recesses which extend upwardly and rearwardly of a roof in use. 9. A roof structure according to either one of Claims 7 and 8 wherein the protuberances are provided towards or at a lower end portion of said carrier frames. 10. A roof structure according to any one of Claims 7, 8 and 9 wherein the panels each comprise ridges extending laterally of the panels in use, said ridges being paral¬ lel or substantially so one with another and being provided with said recesses for receiving the protube¬ rances of associated carrier frames. 11. A roof structure according to any one of Claims 7,8, 9 and 10 wherein the panels are generally rectangular in plan and comprise interlocking sidelock portions and overlapping head and tail portions. 12. A roof structure according to any one of Claims 7, 8, 9, 10 and 11 wherein the panels are of a lightweight insulation material. 13. A roof structure according to any one of Claims 7 to 12 wherein the carrier frames are generally rectangular in plan and each comprises headlap and sidelock engaging clip portions arranged to be a snap-fit, in use, over associated headlaps and sidelocks of tiles carried thereby. 14. A roof structure according to any one of Claims 7 to 13 wherein the carrier frame is provided by a plastics moulding and the protuberances thereof are provided by downwardly extending and forwardly facing hook portions adapted to be received in use in said recesses. 15. A roof structure according to any one of Claims 7 to 14 wherein the tiles are conventional interlocking tiles which are generally rectangular in plan each tile comprising conventional headlap and sidelock portions for interengagement with adjacent tiles on a roof. 16. A roof structure according to any one of Claims 7 to 15 wherein the panels are of moulded polystyrene which panels are fastened to associated pairs of rafters of said structure.

Inventors: LAW FRAZER WILLIAM TIMOTHY, LAW, FRAZER, WILLIAM, TIMOTHY
Applicants: LAW FRAZER WILLIAM TIMOTHY, REDLAND TECHNOLOGY LTD, LAW, FRAZER, WILLIAM, TIMOTHY, REDLAND TECHNOLOGIES LIMITED
Application year: 1994
Main classification: E04B7
IPC codes: E04B7, E04D1, E04D12